Vehicle part packaging system, package, jig, and method

ABSTRACT

A part packaging system and method includes a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package. The system further includes a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package. The jig includes contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.

PRIORITY STATEMENT

This application claims priority to U.S. Provisional Application Ser. No. 61/805,145 filed on Mar. 25, 2013, which is expressly incorporated herein by reference.

BACKGROUND

Vehicle manufacturers are increasingly manufacturing larger, more aesthetically appealing headlights on their vehicles. Due to the more sophisticated design for the headlight, more fragile features are incorporated into the headlight package. For example, mounting tabs and plastic edges tend to be more fragile and more prone to damage than previous models. Heretofore, headlight packaging consisted of a box and an internal restraint/cushioning system. The typical restraint was constructed using corrugated inserts and stretch film. This packaging does not always adequately protect more modern headlight designs and/or involves a relatively time consuming process for packaging each headlight.

SUMMARY

According to one aspect, a part packaging system includes a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package. The system further includes a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package. The jig includes contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.

According to another aspect, a method for packaging a part includes providing a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package. The method further includes installing the package blank within a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, positioning a part on the package blank, and folding the package blank into the enclosed package to contain the part therein. The part has a shape that is complementarily fit by the enclosed package.

According to a further aspect, an enclosed package for a part includes a package blank formed from a single sheet of foldable material folded about fold lines disposed thereon with the assistance of a jig into a box shape. The enclosed package further includes a part enclosed by the package blank when folded into the box shape. The part has a shape that is complementarily fit by the enclosed package.

According to yet another aspect, a jig for folding a package blank into an enclosed package to contain a part includes a body structure configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package. The body structure includes contact portions that correspond to fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a package blank of a vehicle part packaging system according to an exemplary embodiment showing an inner side of the package blank.

FIG. 2 is a plan view of the package blank showing an outer side of the package blank.

FIG. 3 is oblique perspective view of the package blank showing the inner surface of the package blank.

FIG. 4 is a plan view of a package blank according to a more specific exemplary embodiment showing the inner side of the package blank.

FIG. 5 is a front perspective view of a jig of the vehicle part packaging system configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package.

FIG. 6 is a side perspective view of the jig.

FIG. 7 is a perspective view showing the package blank received in the jig and partially folded toward the configuration of the enclosed package.

FIG. 8 is a perspective view similar to FIG. 7 but showing a vehicle part of the vehicle part packaging system received on the package blank.

FIG. 9 is a perspective view showing the package blank folded into the configuration of the enclosed package with the vehicle part contained therein.

FIG. 10 is another perspective view showing the vehicle part being received on the package blank.

FIG. 11 is a top perspective view showing the vehicle part received on the package blank.

FIG. 12 is a side perspective view showing the vehicle part received on the package blank, and particularly showing a mounting tab of the vehicle part positioned adjacent the package blank.

FIG. 13 is a front perspective view showing the package blank being received on the jig.

FIG. 14 is a front perspective view similar to FIG. 13 but showing the package blank being folded along the fold lines by the jig toward the configuration of the enclosed package.

FIG. 15 is a rear oblique perspective view showing the package blank received within the jig.

FIG. 16 is a rear perspective view showing the package blank received in the jig.

FIG. 17 is an enlarged rear perspective view showing the package blank received in the jig.

FIG. 18 is a side perspective view of the package blank being received in the jig.

FIG. 19 is an enlarged side perspective view showing the package blank being received in the jig.

FIG. 20 is a side perspective view showing the package blank being folded to form the enclosed package about the vehicle part received therein.

FIG. 21 is a side perspective view similar to FIG. 20 showing the package blank being further folded toward the enclosed package.

FIG. 22 is a top perspective view of the enclosed package showing a locking tab for securing the configuration of the enclosed package.

FIG. 23 is a top perspective view similar to FIG. 22 but showing the locking tab in its locked position.

FIGS. 24, 25 and 26 show a sequence wherein a side flap of the package blank, and particularly a tab thereof, is received within a corresponding aperture to further lock the configuration of the enclosed package.

FIG. 27 is a process flow diagram illustrating a method for packaging a vehicle part.

DETAILED DESCRIPTION

With reference now to the drawings wherein the showings are for purposes of illustrating one or more exemplary embodiments and not for purposes of limiting same, FIGS. 1, 5, 7, 8 and 9 illustrate a part packaging system including a package blank 10, a jig 12 and a part 14 (e.g., a vehicle part). With specific reference to FIGS. 1-3, the package blank 10 can be formed as a single sheet of foldable material having fold lines 16 (only some shown with reference numbers) disposed thereon and cutout portions (e.g., cutout portions 18, 20) defined therein for enabling the package blank 10 to be folded into a configuration of an enclosed package 22 (FIG. 9). The single sheet of foldable material can be formed of a corrugated material. More particularly, in one exemplary embodiment, the single sheet of foldable material is formed of a corrugated material that is cardboard, though this is not required. In one exemplary embodiment, the single sheet is die cut to form the package blank 10. That is, a single sheet of foldable material is fed into a die (not shown) and the die cuts the single sheet of material into the package blank 10.

The packaging blank 10 includes an inner side 24 (the side shown in FIGS. 1 and 3) and an opposite outer side 26 (shown in FIG. 2). As will be described in more detail below, the inner side 24 contacts the part 14 received on the package blank 10 and the outer side 26 forms an exposed outer side of the enclosed package 22 (see FIG. 9). The package blank 10 can be dimensioned so that the enclosed package 22 has dimensions closely conforming to the shape of part 14. Thus, the enclosed package 22 can likewise have dimensions closely conforming to the shape of the part 14 (i.e., the part 14 can have a shape that is complementarily fit by the enclosed package). FIG. 4 illustrates particular dimensions for the packaging blank 10 according to one specific exemplary embodiment, though it will be appreciated and understood by those skilled in the art that the particular dimensions provided are exemplary only and other dimensions can be used. In addition, the package blank 10 need not be constructed exactly as shown in the illustrated embodiment and can vary widely in order to incorporate the broad concepts disclosed herein.

The part packaging system 10 can further include a cushioning member 28. In the illustrated embodiment, the cushioning member 28 is affixed to the inner side 24 of the package blank 10 for contacting the part 14 and maintaining a position of the part 14 within the enclosed package 22. In an exemplary embodiment, the cushioning member 28 is formed of polypropylene, and in a more specific exemplary embodiment, the cushioning member 28 is formed of microfoam polypropylene. By way of example, the cushioning member 28 can be adhered (e.g., via adhesive) to the inner side 24 of the package blank 10 for contact with the part 14 to inhibit movement of the part 14 within the enclosed package 22. In one embodiment, such as when the cushioning member 28 is polypropylene or microfoam polypropylene, the cushioning member 28 has a coefficient of friction higher than the package blank 10, such as when the package blank 10 is corrugated cardboard for example.

The package blank 10 of the illustrated embodiment includes a base panel 10 a to which the cushioning member 28 is affixed, a side panel 10 b, another side panel comprised of sections 10 c, 10 d, and 10 e, an inner top panel 10 f and an outer top panel 10 g. The package blank 10 further includes end flaps 10 h, 10 i extending from ends of the base panel 10 a, end flaps 10 j, 10 k extending respectively from ends of the side panel 10 b, end flaps 10 l, 10 m extending from ends of the section 10 c, and end flaps 10 n, 10 o extending from ends of the outer top panel 10 g. Further fold lines 16 are defined between adjacent panels, sections and flaps.

With reference to FIGS. 5 and 6, the jig 12 is configured to complementarily receive the package blank 10 and facilitate folding of the package blank 10 into the enclosed package 22. Thus, the jig 12 is for folding the package blank 10 into the enclosed package 22 to contain the vehicle part 14. As illustrated, the jig 12 includes a body structure 34 that is configured to complementarily receive the package blank 10 and facilitate folding of the package blank 10 into the enclosed package 22. The body structure 34, which in the illustrated embodiment is configured as a frame assembly comprising a plurality of elongated tubular frame elements, includes contact portions 36, 38, 40, 42 that correspond to the fold lines of the package blank 10 such that pressure applied to the package blank 10 when received in the jig 12 causes the package blank 10 to fold along the fold lines toward the configuration of the enclosed package 22.

In the illustrated embodiment, the contact portions 36, 38 are laterally spaced apart and extend from a base frame member 44 at a slightly upward oblique angle. The contact portions 40, 42 extend from angled supports 46, 48 at slightly downward oblique angles. As shown in FIGS. 5 and 6, the contact portions 40, 44 are oriented approximately perpendicular relative to the contact portions 38, 40. Moreover, the contact portions 38, 40 are elevated above the contact portions 40, 42. As shown, lower ends 50, 52 of the angled supports 46, 48 can be configured to secure the jig 12 to one side 54 of a planer support 56. Upper ends 58, 60 of the angled supports 46, 48 can be secured to vertically extending members 62, 64, also referred to herein as vertical supports. A raised cross brace 66 can extend between the upwardly extending members 62, 64 elevated relative to the base frame member 44. The base frame member 44 can be secured to a lower cross brace 68 that also extends between the upwardly extending members 62, 64. Smaller angled supports 70, 72 can have upper ends 74, 76 secured to the lower cross brace 68 and lower ends 78, 80 configured to attach to a rear edge 82 of the planer support 56. The jig 12 includes further contact portions 84, 86 constructed as members extending, respectively, from the angled supports 46, 48.

In the illustrated embodiment, as shown in FIGS. 8 and 10-12, the part 14 is a vehicle part, and is specifically illustrated as a vehicle headlamp or headlight, though this is not required and the part 14 can be any part to be packaged (e.g., a non-vehicle part) or could be some other type of vehicle part (i.e., a vehicle part other than a headlight or headlamp). The illustrated vehicle headlamp 14 includes a body portion 14 a and at least one fragile feature extending from the body portion 14 a. As will be described in more detail below, one advantage of the vehicle part packaging system disclosed herein is that the at least one fragile feature can be spaced apart from walls of the enclosed package 22 (wherein the walls are the panels and flaps of the package blank 10) and are inhibited from contacting the walls of the enclosed package 22. In the illustrated embodiment, the at least one fragile feature includes a mounting tab 14 b extending from approximately an intersection of a bottom side 14 c of the body portion 14 a and an outer lateral side 14 d of the body portion 14 a. Additionally, in the illustrated embodiment, the at least one fragile feature includes at least one plastic edge tip extending from a lateral side of the body portion 14 a.

Specifically in the illustrated embodiment, the at least one plastic edge tip includes a pair of spaced apart inner plastic edge tips 14 e disposed along an inner lateral side 14 f of the body portion 14 a and an outer plastic edge tip 14 g disposed along the outer lateral side 14 d of the body portion 14 a. As shown, each of the at least one plastic edge tips 14 e and 14 g can include an aperture size to receive a fastener (not shown) for mounting the vehicle headlamp 14 to an associated vehicle (not shown). Additionally, the vehicle headlamp 14, and particularly the body portion 14 a, can include a lens 14 h. Advantageously, the cushion member 28 can be interposed between the lens 14 h and the enclosed package 22. The cushioning member 28 specifically functions to maintain a spaced apart relation between a portion of the vehicle part 14 (e.g., the lens 14 h when the vehicle part 14 is a vehicle headlamp) that the cushioning member 28 contacts and the enclosed package 28.

With reference to FIG. 27, a method for packaging a vehicle part will now be described. In particular, the method will be described in association with the vehicle part packaging system described hereinabove, though this is not required and it is to be appreciated that the method for packaging a vehicle part to be described below can be used with other vehicle part packaging systems. In the method, a package blank 10 formed as a single sheet of foldable material having fold lines 16 disposed thereon and cutout portions defined therein is provided at 200, which can enable the package blank 10 to be folded into a configuration of the enclosed package 22. The package blank 10 is installed within the jig 12 at 202 that is configured to complementarily receive the package blank 10 and facilitate folding of the package blank 10 into the enclosed package 22. The vehicle part 14 is positioned on the package blank 10 at 204. In particular, the vehicle part 14 can be positioned on the package blank 10 after the package blank 10 is installed within the jig 12. Once the vehicle part is positioned, the package blank 10 can be folded into the enclosed package 22 at 206 to contain the vehicle part 14 therein. As discussed above, the vehicle part 14 has a shape that is complementarily fit by the enclosed package 22.

More particularly, installing the package blank 10 within the jig 12 is shown in FIG. 13. Specifically, and as shown, the package blank 10 is inserted into the jig 12 with the inner side 24 facing up so that the cushioning member 28 affixed thereto is visible. The package blank 10 is inserted into the jig 12 (i.e., advanced toward the upwardly extending members 62, 64) until the package blank 10 is stopped from further movement by the upwardly extending members 62, 64. Next, pressure can be applied to the crease area 100 above the cushioning member 28. Specifically, pressure can be applied by pushing firmly downward into the jig 12 at the crease area 100. Accordingly, installing the package blank 10 into the jig 12 includes applying pressure to the package blank 10 such that the contact portions 36, 38, 40, 42 of the jig 12 corresponding to the fold lines 16 of the package blank 10 force the package blank 10 to fold along the fold line 16 toward the configuration of the enclosed package.

The method can further include installing the cushioning member 28 on the package blank 10 prior to positioning the vehicle part 14 on the package blank 10 for contacting the vehicle part 14 and maintaining the position of the vehicle part 14 within the enclosed package 22. More specifically, installing the cushioning member 28 on the package blank 10 can occur prior to the package blank 10 being inserted into the jig 12 or could occur after the package blank 10 is installed in the jig 12. As already mentioned, installing the cushioning member 28 can include affixing or adhering the cushioning member 28 on the package blank 10. With additional reference to FIG. 14, applying pressure to the package blank 10 can further include having the jig 12 force projection portions of the package blank 10 inward to form a shaped cavity within the enclosed package 22 for complementarily fitting the vehicle part 14. In particular, the projection portions can be the sections 10 c, 10 d, 10 e of the package blank 10 which fold inward as shown in FIG. 14. This is facilitated by the contact portions 36, 38 engaging against the sections 10 c, 10 d, 10 e. Additional cutout portions 102 disposed on flanking sides of the creased area 100 further facilitate inward folding of the sections 10 c, 10 d, 10 e.

FIGS. 15, 16, 17, 18 and 19 further illustrate the positioning of the package blank 10 relative to the jig 12 as pressure is applied to the creased area 100. As shown, installing the package blank 10 within the jig 12 includes, after the step of moving the package blank 10 into the jig until the vertical supports limit further movement, applying pressure at a target location (i.e., the crease area 100) on the package blank 10 such that the package blank 10 folds along the fold lines 16 and the jig 12 erects a back wall (i.e., sections 10 c, 10 d, 10 e) of the enclosed package 22 and forces the projection or contact portions 36, 38 inward toward an interior of the enclosed package 22. During this step, three elements of assembly occur with respect to the enclosed package 22. First, the jig 12 assists by erecting the back wall of the enclosed package 22. Second, the contact portions 40, 42 of the jig 12 cause the sections 10 c, 10 d, 10 e to indent inwardly. Thirdly, the jig 12 via the angled supports 46, 48 and contact portions 84, 86 assist in folding the end flaps 10 h-10 o in sequence to form ends of the enclosed package 22.

Advantageously, once the package blank 10 is in this position (i.e., partially folded), the jig 12 will hold the package blank 10 in position. This affords an opportunity to position the vehicle part 14 on the package blank 10 in its partially folded position. Specifically, the vehicle part 14 can be positioned on the package blank 10 as shown in FIG. 8. When the vehicle part 14 is a vehicle headlamp, the lens 14 h of the headlamp 14 can be positioned to contact the cushioning member 28. The cushioning member 28 can prevent or inhibit scuffing and/or rubbing against the lens 14 h of the headlamp 14. In addition, the cushioning member 28 can increase the coefficient of friction, particularly relative to the package blank 10, thereby resulting in less movement of the vehicle part 14 within the enclosed package 22

Next, the inner top panel 10 f can be folded over the vehicle part 14 as shown in FIG. 20 and the side panel 10 b can be folded against the vehicle part 14 and the outer top panel 10 g can be folded over the inner top panel 10 f as shown in FIG. 21. The outer top panel 10 g can have a locking tab 104 that is received within a corresponding aperture 106 of the inner top panel 10 f to lock the enclosed package 22. Next, the end flaps 10 n, 10 o can be folded down and respective tabs (tab 108 shown in FIG. 24) can be inserted into corresponding slots (slot 110 shown in FIG. 24). The enclosed package 22 is now complete and can be removed from the jig 12.

Advantageously, the vehicle part packaging system, package, jig and method described herein in its various embodiments protects the vehicle part 14 to be packed while using less material and reducing the packaging cycle time. Moreover, any fragile portions of the vehicle part 14 are protected. In particular, the enclosed package 22 secures the vehicle part 14 in a set position and inhibits movement thereof within the enclosed package 22 and simultaneously isolates any fragile areas of the vehicle part 14. An additional advantage is that the package blank 10 provides a single layer. That is, no outer pack is required beyond the package blank 10 when folded into the enclosed package 22.

It will be appreciated that various of the above-disclosed and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. 

1. A part packaging system, comprising: a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package; and a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the jig including contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.
 2. The part packaging system of claim 1 further including: a vehicle part received on the package blank and being contained within the enclosed package, the vehicle part having a shape that is complementarily fit by the enclosed package.
 3. The part packaging system of claim 2 wherein the package blank is dimensioned so that the enclosed package has dimensions closely conforming to the shape of the vehicle part.
 4. The part packaging system of claim 2 wherein the vehicle part is a vehicle headlamp, wherein the vehicle headlamp includes a body portion and at least one fragile feature extending from the from the body portion, and wherein the at least one fragile feature is spaced apart from the walls of the enclosed package and inhibited from contacting the walls of the enclosed package.
 5. The part packaging system of claim 4 wherein the vehicle headlamp includes a lens and the vehicle part packaging system further includes a cushion member is interposed between the lens and the enclosed package.
 6. The part packaging system of claim 2 further including: a cushioning member affixed to an inner side of the package blank for contacting the vehicle part and maintaining a position of the vehicle part within the enclosed package, the cushioning member further maintaining a spaced apart relation between a portion of the vehicle part that the cushioning member contacts and the enclosed package.
 7. The part packaging system of claim 1 wherein a cushioning member is adhered to an inner side of the package blank for contact with a part received on the package blank to inhibit movement of the part within the enclosed package.
 8. The part packaging system of claim 1 wherein the single sheet is formed of a corrugated material and is die cut to form the package blank.
 9. The part packaging system of claim 1 wherein the package blank includes inner side and an opposite outer side, the inner side configured to contact a vehicle part received on the package blank, and the outer side forming an exposed outer side of the enclosed package.
 10. A method for packaging a part, comprising: providing a package blank formed as a single sheet of foldable material having fold lines disposed thereon and cutout portions defined therein for enabling the package blank to be folded into a configuration of an enclosed package; installing the package blank within a jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package; positioning a part to be packaged on the package blank; and folding the package blank into the enclosed package to contain the part therein, the part having a shape that is complementarily fit by the enclosed package.
 11. The method of claim 10 wherein installing the package blank within the jig includes applying pressure to the package blank such that contact portions of the jig corresponding to the fold lines of the package blank force the package blank to fold along the fold lines toward the configuration of the enclosed package, and wherein applying pressure to the package blank includes the jig forcing projection portions of the package blank inward to form a shaped cavity within the enclosed package for complementarily fitting the part.
 12. The method of claim 10 wherein the package blank includes overlapping sides secured together via a tab of the overlapping sides being received in an aperture of the overlapping sides.
 13. The method of claim 10 wherein the package blank includes end flaps defined by the cutout portions, the end flaps overlapping one another during installing of the package blank within the jig and folding the package blank into the enclosed package.
 14. The method of claim 10 further including: installing a cushioning member on the package blank prior to positioning the part on the package blank for contacting the part and maintaining a position of the part within the enclosed package.
 15. The method of claim 14 wherein the part is a vehicle headlamp that includes a lens and the cushion member is interposed between the lens and the enclosed package in contact with the lens.
 16. The method of claim 10 wherein installing the package blank within the jig includes moving the package blank into the jig until vertical supports of the jig limit further movement of the package blank into the jig, and wherein installing the package blank within the jig further includes, after the step of moving the package blank into the jig until the vertical supports limit further movement, applying pressure at a target location on the package blank such that the package blank folds along the fold lines and jig erects a back wall of the enclosed package and forces projection portions inward toward an interior of the enclosed package.
 17. An enclosed package for a part, comprising: a package blank formed from a single sheet of foldable material folded about fold lines disposed thereon with the assistance of a jig into a box shape; and a part enclosed by the package blank when folded into the box shape, the part having a shape that is complementarily fit by the enclosed package.
 18. The enclosed package of claim 17 wherein the part is a vehicle headlamp.
 19. The enclosed package of claim 17 in combination with the jig, the jig configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the jig including contact portions that correspond to the fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package.
 20. A jig for folding a package blank into an enclosed package to contain a part, comprising: a body structure configured to complementarily receive the package blank and facilitate folding of the package blank into the enclosed package, the body structure including contact portions that correspond to fold lines of the package blank such that pressure applied to the package blank when received in the jig causes the package blank to fold along the fold lines toward the configuration of the enclosed package. 